Travancore Titanium Products Industrial Training report

TRAVANCORE TITANIUM PRODUCTS LTD THIRUVANANTHAPURAM Industrial Training Report

Submitted in partial fulfillment of the requirements for the award of the degree of Master of Technology in Industrial Engineering and Management

By AJURAM K SALIM

(Roll No.: M100462ME)

KAILAS SREE CHANDRAN


SHAJID P P


Department of Mechanical Engineering NATIONAL INSTITUTE OF TECHNOLOGY CALICUT June 2011

Department of Mechanical Engineering NATIONAL INSTITUTE OF TECHNOLOGY CALICUT June 2011

CERTIFICATE This is to certify that the report entitled “TRAVANCORE TITANIUM PRODUCTS LTD, THIRUVANANTHAPURAM” is a bonafide record of the Industrial training done by AJURAM K SALIM (Roll No.:M100462ME), KAILAS SREE CHANDRAN (Roll No.:M100447ME), SHAJID P P (Roll No.:M100465ME), in partial fulfillment of the requirements for the award of the degree of Master of Technology in Industrial Engineering and Management from National Institute of Technology Calicut.

Dr. R. Sridharan Course Coordinator Dept. of Mechanical Engineering

Place : NIT Calicut Date : 16/06/2011

ACKNOWLEDGEMENT This is a report on In-Plant training at Travancore Titanium Products Ltd during 16th May 2011 to 16th June 2011 by the 2nd semester MTech Industrial Engineering & Management students of National Institute of Technology, Calicut. We take this opportunity to express our hearty thanks to the members of the organization who helped us a lot during this period. We also sincerely thank our college and management for arranging the in-plant training.

AJURAM K SALIM KAILAS SREE CHANDRAN SHAJID P P

CONTENTS List of Tables

i

List of Figures

ii

1

Introduction

01

1.1

Company Profile

01

1.2

Historical Background

01

1.3

Products Produced

02

2

Organization Set-Up

06

3.

Departmentation

09

3.1

Introduction

09

3.2

Production Department

10

3.3

Legal Department

12

3.4

Personnel Department

15

3.5

Commercial Department

21

3.6

Research and Development Department

22

3.7

Materials Department

26

3.8

Human Resource Development and Administration Dept

28

3.9

Engineering Department

29

3.10

Finance Department

32

3.11

Safety Department

36

3.12

Medical Department

38

3.13

Security Vigilance Department

39

3.14

Project Department

40

3.15

Marketing Department

42

4.

5.

Plant and Processes

44

4.1

Titanium Dioxide Plant

44

4.2

Sulphuric Acid Plant

54

Conclusion

Reference

68 69

LIST OF TABLES 1.1

Product Consumption Pattern

03

2.1

Executive Staff

06

3.1

Protective Equipments

37

4.1

Composition of illmenite

44

4.2

Temperature and conversions in each stage of the 4-pass convertor

66

LIST OF FIGURES 2.1

Organization Chart

8

3.1

Production Department: Line of Authority

12

3.2

Legal and Personnel Department: Line of Authority

15

3.3

Commercial Department: Line of Authority

24

3.4

Research and Development Department: Line of Authority

25

3.5

Material Department: Line of Authority

27

3.6

HRD and Administration Department: Line of Authority

30

3.7

Finance Department: Line of Authority

35

3.8

Safety Department: Line of Authority

38

3.9

Medical Department: Line of Authority

39

3.10

Security Vigilance Department: Line of Authority

40

3.11

Project Department: Line of Authority

41

3.12

Marketing Department: Line of Authority

43

4.1

Production Process (Diagrammatic Presentation)

46

4.2

Flow Diagram of Titanium Dioxide Plant

51

4.3

Flow Diagram of Sulphuric Acid Plant

56

Industrial Training Report: Travancore Titanium Products

CHAPTER 1 INTRODUCTION 1.1 COMPANY PROFILE The Travancore Titanium Products Limited is the pioneering enterprise in India for producing the pigment grade Titanium Dioxide. This product is produced from the minerals like Ilmienite, Rutile etc. occurring in the beach sands of Chavara in Kollam district, Kerala Manavalakurichi of Kanyakumari district, Tamil Nadu and Chatrapur in Orissa.

The

Travancore Titanium Products Limited was incorporated on the 18th December 1946. It is located at Kochuveli about 10km to the North West of Thiruvananthapuram City. The main product of Travancore Titanium Products Limited is Titanium Dioxide. 1.2 HISTORICAL BACKGROUND Till 1925, the presence of Titanium Dioxide in the black sands of Kollam beaches was not known. The coir products from Kollam to be exported frequently were dried on these beaches. When such coir products were exported, some radioactive properties was noticed. The Germans send a delegation to Kerala to conduct experiments with the black sand. They found that the sand has some radioactive properties owing to the presence of Thorium. They also found that the sand was rich in Titanium. This beach sand containing valuable Titanium Dioxide was exported to Europe till 1946, when M/s Travancore Titanium Products Limited, was incorporated with the sole objective of producing pigment grade Titanium Dioxide (TiOP2). When the British were ruling our country, they exported Ilmenite, which is the raw material for producing Titanium Dioxide for British Titan Products, and imported their products to India.

Till 1946, the product was imported through the Imperial Chemical Industries,

Calcutta. T.T.P. Ltd was incorporated in 1946 and the unit was promoted by the princely administration of Travancore, in technical collaboration with the British Titan Products Ltd, U.K. The credit for launching this maiden venture goes to His Highness Shri.Chithira Thirunal Balaramavarma Maharaja of Travancore and his Dewan Sir. C. P. Rameswamy Iyer.

Page

was with a managing agency called India Titan Products.

1

Even though the Maharaja held 51% share capital the administrative control of the company

National Institute of Technology Calicut


The production of Titanium dioxide commenced in the year 1951 and the initial capacity of the plant was 5 tons per day. In 1960, the Government of Kerala took over the management of the concern and the production capacity was raised to 10 tons per day. Along with this expansion, the company commissioned its first sulphuric Acid Plant producing 50 tons of acid per day for captive consumption. In 1963, the capacity of the TiO2 plant was further increased to 18 tons per day and the second sulphuric Acid plant of 50 tons per day capacity started production. Another major expansion programme was completed in 1973, which augmented the capacity to 45 tons per day. In 1976-78 under the chairmanship of Dr.Vaseer, a committee was formed to study the production capacity of the plant. The committee estimated the production capacity as 15000 tons per months. A third acid plant with pollution control measures of 300 tons per day production was also started in 1996 to meet the increased requirement of sulphuric acid. At the beginning, Imperial Chemical Industrial was the sole selling agents for T.T.P. Ltd. After sometimes, they stopped to function as the selling agents and T.T.P resorted to direct marketing till 1979. In 1979, the government of Kerala appointed a sole selling agency called the Kerala State Industrial Products Trading Corporation Limited (KSIPTC) to take over the trading and marketing activity of the company. The Travancore Titanium Production Ltd now has no major competitors within the country. There are two private companies-one at Tuticorin (Kilburn Chemicals) and another at Calcutta (Colmack Industries) which pose minute competition. 1.3 PRODUCTS PRODUCED Travancore Titanium Products Ltd is one of the largest industries in India that produces Titanium Dioxide (TiO2). In addition to Titanium Dioxide, the company is manufacturing Pottassium Titanate, Sodium Titanate, low Phosphorus and Special grade Titanium Dioxide in comparatively in small quantities.

Rutile Grade



Anatase Grade

These two grades of Titanium Dioxide are chemically the same but their physical properties differ from each other. The company deals with the production of Titanium Dioxide, which


Page



2

Titanium Dioxide (TiO2) is a white pigment and there are two grades of Titanium Dioxide.


belongs to Anatase grade. The major raw material used for production is Ilmenite. The most important commercial use of Ilmenite is the manufactures of Titanium Dioxide pigment. Ilmenite is a compound of the oxides of iron, Titanium and traces of other elements. The separation of Titanium Dioxide can be done through the sulphate route or chloride route. The Travancore Titanium Product plant is based on the Sulphate Route. Properties of Titanium Dioxide Titanium Dioxide is of non-toxic nature having chemical stability.

It possesses higher

refractive index and hence it is used to make paints. It is extremely heat resistant and this enhances the capacity of the substance incorporated with Titanium Dioxide to with stand the effect of the chemical environment and climatic conditions. It has got high pacifying power ie, the power to change transparency. So it is used in plastics to make it opaque. Its uniformity of composition enables it to mix with any material without losing its natural properties. Hardness of the material provides good resistance to mechanical shock. It possesses tinting strength ie, the particles are so minute that it occupies a larger surface area. Table 1.1 Product Consumption Pattern Paint

55%

Rubber

14%

Textile

11%

Paper

05%

Cosmetics

04%

Synthetic fibers

04%

Ceramic & Enamel Wares

03%

Printing Ink

02%

Linoleum

01%

Others

01% 100% Page

3

Total



Indian Industries Where Titanium Dioxide Is Used As Raw Material 

Textiles

CTM Textiles Rajkamal Processors Sharda Textile Mills

Leo Rubber Paragon Rubber Relaxo Footwear 

Paper

Bishen Dyeing,Printing & Weaving Mills

Pudumjee Pulp & Paper

Bimal Dyeing, Printing & Weaving Mills

Balakrishna Paper Mills



Ink

Kores (India) Ltd. JBA Printing Ink Ltd. Coates of India Rainbow Ink & Varnishes 

Cosmetics

Hindustan Lever Ltd.

ITC - Tribeni Tissues Sreevindhya Paper Mills Sreekrishna Paper Mills Security Paper Mills, Goverment of India 

Leather

National Leather Cloth 

Paints

Colgate Palmolive

Asian Paints (I) Ltd.

Godrej soaps

Goodlass Nerolac Paints

Karnataka soaps & Detergents

Beepee Coating



Rubber

Bata (India) Ltd. Lakhani Footwear Madras Rubber Factory Elastrex Polymers

Special Paints Rajdoot Paints Hem Paints Berger Paints 

Chemicals

Camphor & Allied Products

Madhura Rubber

Dr. Beck & Company


Page

4

Prestone Industries

Industrial Training Report: Travancore Titanium Products Jay Industrial Chemicals The National Paints & Chemicals 

Plastics

Hycount Plastics Padinjarekkara Rubber & Plastics Sudhakar PVC



Cellofine Paper

Travancore Rayons Limited 

Electronic Industries

Videocon Narmada Electronics Gujarat Mulco Electronics

Page

5

Sudhakar Plastics

Nuchem Plastics



CHAPTER 2 ORGANISATION SET-UP Travancore Titanium Products is a public sector undertaking headed by the Managing Director, Shri.P.H.Kuriyan was the Managing Director during my organizational study. Board of Directors 

Chairman - (The Principle Secretary in Industries Department of Kerala Government.)



Managing Director



Director - (Additional Secretary in Finance Department of Kerala Government)



Executive Director



Director - (A Member of Legislative Assembly)



Director – (A Special Secretary to Industries Departmental of Kerala Government) Table 2.1 Executive Staff Mangers

20

Dy. Managers

35

Other Executives

127

Supporting Staffs and workers

1337

Total

1519

Banker State Bank of India Registered Office Travancore Titanium Product Ltd Kochuveli.P.O Thiruvananthapuram

Page

6

Kerala.



ORGANIZATIONAL CHART OF TRAVANCORE TITANIUM PRODUCTS LTD Managing Director

C.E

M (R&D)

Finance Controller

SS &VO

P.Mgr Trg Mgr

Prod Mgr

Dy Prod & Plant Mgr

Asst Plant Mgr

Foremen

Dy C.Es

Exec Engg

Asst Exec Engg

Asst Engg

Mgr QC & TS

Dy Mgr

Asst Mgrs

Chemists


Mgr (P&A)

Mgr Safety

Security Officer

Asst P.Mgr

Dy F.Mgr

Company Secretary

Asst Security Officer

Personal Secretary To M.D

Finance Mgr

Chief Commercial Manager

Commercial Mgr

Dy Mgr P &A

Asst

Asst

Mgr

Mgr

Legal Mgr

Dy Comm Mgrs

Asst Mgr

Company Medical Officer

Materials Mgr

Dy Materials Mgrs

Pharmacists

Asst Mgr

Nurse

Training Officer

Section Officer

Section Officer

S.O

S.O

S.O

7

CP Mgr

Executive Director (C &A)

Chief Projects Mgr

Page

General Manager Works


Decision Making Authority The decision making authority in T.T.P Ltd. Vests with the Titanium Management Council (TWC). The council has M.D. as the Chairman and all Department head as members. The decisions taken by TMC are based on government policies. The TMC meets on the first day of every month prepares, the activities for the next month such as monthly production target, monthly sales target etc. as review of the previous monthly meeting is also done. Quality System Certification

Page

8

ISO 9001-2000 Certificate



CHAPTER 3 DEPARTMENTATION 3.1 INTRODUCTION Departmentalization is the efficient and effective grouping of jobs into meaningful work units to coordinate numerous jobs-all the expeditious accomplishment of the organisation‟s objectives. This creates Flexibility, Adaptability and unit of action within the firm. The various departments in T.T.P. are as follows: Production Department



Financial Department



Personnel Department



Engineering Department



Project Department



Research & Development Department



Security & Vigilance Department



Safety Department



Medical Department



Material Department



Legal Department



Commercial Department



Training Department



Marketing Department Page

9




Industrial Training Report: Travancore Titanium Products 3.2 PRODUCTION DEPARTMENT The main product of Travancore Titanium Products Ltd is Titanium Dioxide pigment. So considering the production, the production department becomes the vital department in TTP Ltd. The primary objective of TTP is to produce pigment grade Titanium dioxide as per the capacity utilization target approved by the Management maintaining optimum quantity standards of both Anatase and Rutile Grades. The total production capacity of the plan is 46 tons/day. The production department has co-ordination with all other departments. Chief Production Manager heads the department. There are four sections in production department namely Titanium Dioxide Section, sulphuric Acid Plant (SAP), Mangerial Information System (MIS), Raw Materials and Packing Section (RM &PS) each headed by Production Managers. By the MIS, the department makes the co-ordination with other departments easier. The Titanium Dioxide Section has two ends, Black End and White End each headed by Deputy Production Managers. The Production department is directly responsible for maintaining optimum quantity. Standards of both Anatase and Rutile grades. Child Production Manager is responsible for achieving this objective of TTP by integrating directing and controlling the work of Titanium dioxide, production of sulphuric Acid etc. Sulphuric Acid is also another product for which the raw material Sulphur is importing from Chile and Argentina. The production department of TTP has may important functions, which are as follows 

To prepare detailed production plan in consultation with General Manager (works) which must be consistent with company‟s production objective.



To prepare detailed raw material plans and ensure the incoming quality standards their proper usage etc.



Constantly evaluating alternate source of raw materials, direct trails of the same and to help the management to firm up the sources.



Integrate, direct and control efforts of production of Sulphuric Acid pigments, dispatch raw materials etc. resulting in fulfillment of planned targets for production

Receiving of raw materials and packaging of final products.

Page



10

and provide overall supervision of Titanium dioxide production.


Industrial Training Report: Travancore Titanium Products 

Integrating the department itself with Research and Development department for identifying solutions to long-term problems.



Carryout investigations and guide management on long term measures towards achievements of the goals of expansion in the areas of production and quality.



Integrate production efforts with maintenance to ensure implementation of production and maintenance schedules and to avoid breakdowns by helping maintenance under take jobs on time basic etc.

The Production Process The main product of TTP Ltd is Titanium dioxide. The raw material used is ilmenite, which is from IRE Chavara. The production process is as follows. Ilmenite, a mixed oxide of Titanium, ferrous iron and ferric iron is grounded in ball mills to fine power which is reached with sulphuric acid is specially designed digesters. There are reinforced concrete tanks lined with lead and acid resistant bricks. The highly exothermic reaction is completed by passing steam. The porous cake obtained as product is dissolved in dilute sulphuric acid, thus Titanium goes into solution as Titanium oxy-sulphate. The ferric iron present is reduced to ferrous iron completely. Using scrap iron the former interferes at the succeeding stage of precipitation of hydrated Titanium by co-precipitation. Reduced crude liquor is closed with setting agents and sent through large setting tanks to remove the sludge consisting mainly of unreacting ilmenate and silica. The clear overflow from settler is concentrated into a specified extends and then charged into precipitation tanks. On boiling by injecting system the Titanium content gets precipitated as hydrated Titanium. It is filtered over drum type rotary vacuum filters. Any ferric iron still present is reduced to washable ferrous form by leaching the pulp with dilute sulphuric acid and Aluminum powder. It is washed further and then treated with small quantities of certain chemicals, which help to develop the pigmentary properties. The treated pulp is dewatered to 40% solids and then into big kerosene filled rotary kilns. The moisture get removed first and then sulphuric acid decomposes and the oxides of sulphur escapes out.

At final stage of heating in kilns

Page

of average size of 0.4 microns packed in 25kg bags and marketed.

11

crystalline properties gets carried to pendulum type mills and pulverized to very fine particles


Industrial Training Report: Travancore Titanium Products Another main product of TTP is sulphuric acid which is prepared by Double Contact process using Vanadium pent oxide (V2O2) catalyst. In addition to these products the company is also producing potassium tartarate and low phosphate of Titanium dioxide, which finds better application in welding and including on a semi commercial.

CHIEF PRODUCTION MANAGER

Production Manager

Production Manager

Production Manager

Plant Monitoring

Sulphuric Acid Plant

Production Manager Raw Materials

Dy.

Dy.

Dy.

Dy.

Dy.

Production

Production

Production

Production

Production

Manager

Manager

Manager

Manager

Manager

Asst. Manager

Foreman

Figure 3.1 Production Department : Line Of Authority

3.3 LEGAL DEPARTMENT

Page

Department is responsible for representing the company in legal matters.

12

The TTP‟s Legal Department is headed by the Chief Manager (Legal and Personnel). This


Industrial Training Report: Travancore Titanium Products Objectives 

Prevention and settlement of industrial dispute.



Represent the company in the Court of Law.



File cases against external parties.

The settlement of industrial disputes is done by two ways, namely 1. Voluntary Agreement 2. Statutory Procedures Voluntary agreement includes code of discipline and workers participation in management. Statutory procedure includes Works committee, conciliation officers, arbitration and adjudication. The legal department has to conduct domestic enquiry when disputes arises and also investigates on the violation of disciplinary levels. Main Functions The department is to render legal opinion/advice on matters referred from various other departments of the company on subjects varying from recruitment and service matters to contract and commercial transactions. i.

Recruitment

To the various categories of posts in Managerial Cadre and Subordinate Service, recruitment is effected through PSC /Employment Exchange or by Direct notification, and under dyingin-scheme. ii.

Service Matters

Service matters ranging from eligibility of the candidate for promotion to a particular post, deciding the merit, up gradation (in lieu of promotion) increments/anomaly etc may call for legal advice/opinion.

A dispute of difference between the parties in any of the above matters such as retirement/service matters, contract may lead to litigation at various venues such as Industrial


13

Conduct of Cases

Page

iii.

Industrial Training Report: Travancore Titanium Products Tribunal/Labor Court, Civil Courts, High Courts of Departmental Authorities such as sales Tax/Transport Commissioner / Tribunals of Central Excise Commission/ Collector (Appeals), Central Excise and Gold Control Appellate Tribunal (CEGAT). In case of purchase /Contract disputes are also referred to arbitration. iv.

Disciplinary Proceeding

Being an establishment employing above 1300 employees (managerial and Subordinate Service), naturally of discipline may come up most often. Having got the certified standing orders, and the misconducts well defined therein, any act affecting discipline cannot but be taken cognizance of disciplinary proceedings starts with issuance of charge sheet with details of the alleged misconduct and calling for the delinquent‟s explanation which is if not found satisfactory, domestic enquiry is ordered: this involves posting of the Enquiry officer and presenting officer, culminating in the Enquiry report of the enquiry officer and award of punishment, if found guilty, based on the enquiry report. v.

Commercial Transactions

In the course of business, the company was to enter in to agreement s/contacts with various suppliers, customers and contractors for supply of material, servicing of equipment supplied, executing of contract etc. throughout the country and even aboard at times. Documents embodying these contracts have to be drafted/approved/ vetted by this Dept. vi.

Financial Matters

Mainly the financial matters referred for legal opinion relate to levy of charges as Excise duty /MODVAT claims. Sales tax etc., on materials purchase/ sold by the company. There being a bulk of status in the country governing industry/ labour in addition to the ordinary enactments on civil matters, a legal issue may spring up in anything related to the

Page

14

company any time, warranting involvement of Legal Department.



Chief Manager Legal & Personnel

SO Sports

Manager P &A

Dy. Manager (I) P & A

Dy. Manager (II) P & A

Asst, Manager

Coach/ plyers

Section Officer

LWO

Section Officer

Officer SD

SO legal

Legal section staff

Section Officer

Cant. Supt

Cant.Supt

Ctn. Staff Figure 3.2 Legal and Personnel Department: Line of Authority 3.4 PERSONNEL DEPARTMENT Human Recourse is the main asset of any organization. Therefore managing the human resources is the most important functions of any organization. So it is essential for any organization to fix a separate department for the management of human resources. TTP has

This departmental is mainly responsible for personal functions of the company for resulting

Page

in timely action for maintaining smooth industrial relations leading to employee‟s morale and

15

an efficient Personal Department, which is headed by Chief Manager (Legal & Personal).


Industrial Training Report: Travancore Titanium Products productivity. The personal department renders all personal and establishment services to all personal and establishment services to all persons. The primary objective of the personal department includes establishment of industrial relations, welfare, salaries and wages, recruitment etc. the other objectives of the department includes. To provide leadership for management of industrial relations and employee‟s welfare functions of the company. 

To provide basics for corporate strategies and policies for maintenance of industrial peace and for workers motivation.



For evolving system of prompt attention and redressal of employee‟s grievance and prevention of the same.



Administering the different committees for employee‟s participation.



Evolve and update practices for checking incoming and outgoing of materials and persons.



Implementing the standing orders pertaining in the company.

The personal department has many important functions to do. The Staffing Functions of personal department following activities. 1. Man power planning & identification One of the major functions of this department is the planning of the required manpower and identification of the vacancies present in the company. The number of employees required for the company was planned by this department. 2. Recruitment Another important function of personal department is the recruitment of the right persons in the right place at right time. It is time first process by which employment is provided to the adequate manpower resources.

It is the positive process of searching for prospective

employees and circulating them to apply for the jobs. The sources of recruitment can be

Page

16

classified as:


Industrial Training Report: Travancore Titanium Products a. Internal Sources Internal sources include personal already on the payroll of an organization i.e. It present employees. Another method in internal sources is by direct recruitment of employees. b. External Sources The term external sources indicate the source outside the enterprise. The main sources are by PSC & Employment Exchange. The PSC conducts examination for the candidates according to the PSC Act of 1970 for the Clerical, Typist & Grade V vacancies. The outside source include: 

New entrants to the labour force.



The unemployed with wide range of skills.



Retired experienced person.

Dying-in-harness scheme The company appoints several persons by this scheme.

If any employee dies before

retirement, then the company offers job for his children or any member of family according to their qualification. Sports Quota The company has 3 seats in the Sports Quota. The company selects persons who participated in national and state level in football and volleyball. 3. Selection It is a process of choosing the right person among the applications. The various stages involved in selection process are. a. Security of applications received:

Applications having required educational qualifications and experience.



Applicants who didn‟t have required qualifications are rejected.

Page



17

The applications received for a particular post are categorized as


Industrial Training Report: Travancore Titanium Products b. Preliminary Interview Usually at this stage unsuitable candidates are eliminated even though they have required educational qualification. c. Black Application Forms Selected applications are given blank applications form to fill the individual bio-data of the candidate. d. Written Test This is conducted for getting additional information about the candidate.

It includes

intelligence test, personality test, aptitude test etc. e. Interview Here, the basic idea is to find the overall suitability of the candidate for the job. It also provides opportunity to give relevant information about the organization to the candidates. f. Physical Examination Physical examination is carried out ascertain the physical standards and fitness of prospective candidate. g. Final Selection After the candidate has passed all the stages above mentioned, he has given an appointment offer letter.

Usually, candidates are appointed as probationary period for few months

ranging, from 6 months to one year. After successful completion of probationary period, he is appointed on permanent basis. h. Placement and Induction Placement concerns with placing of employees at right place where they are required. Induction deals with oriented the employee to the company and its surrounding. Usually the

Page

18

induction-training period is 1 week.


Industrial Training Report: Travancore Titanium Products 4. Performance Appraisal Performance appraisal a systematic evaluation of present potential capabilities of personnel by their superiors. It is the process of estimating or judging value status of a person. The main objectives of performance appraisal are: 

To provide systematic judgement to back up salary increments, transfers etc.



Means of telling the employees how he is doing or performing his work and suggesting the needed changes in his behaviour



It is used as a base for coaching and counseling the individual by his superior

5. Promotion Advancement within an organization is ordinarily labeled as promotion, which involves a change from one job to another that is better is terms of status and responsibility. Change to higher job is accompanied by increases in pay and privileges.

For every change for

promotion, 3 persons are considered. Basis for promotion in TTP are attendance service, performance, seniority, test/interview etc. 6. Transfer Transfer refers to shifting of a person from one job to another without reference to change in responsibility or remuneration. In TTP, transfer is given for administrative staff only. 7. Retirement Retirement means the situation when the employee being terminated service on reaching a fixed age. The age of retirement of TTP is 60 years. At the time of retirement the employee will provided with provided fund, gratuity etc., one golden ring is given to every retiring person by Retire men‟s association TTP. 2 service awards were given to those workers who completed 15 years at the time of retirement. One gift check was given to those who completed 20 years. TRC and TLSS There is a Recreation Club present in TTP known as Titanium Recreation Club (TRC) for

(TLSS). They provide loans and chit funds for employees.


Page

There is a Co-operative Society in TTP known as Titanium Labour Sahakarana Sangam

19

providing recreation facilities to the employees. TRC has family welfare committee.

Industrial Training Report: Travancore Titanium Products Wages & Salary TTP gave fair remuneration to its employee in order to increase their morale thus by increasing the productivity. There is two types of pay scale present. One is for subordinate service and other for officer service. The last but working day is the Salary day. Incentives & Rewards TTP also gives incentives and rewards to employees. The incentive like Dearness Allowance Fringe Benefit are given to the employees. On festivals like Onam etc., the employee‟s get performance cum motivation. Industrial Relations TTP marinating an excellent relationship with its employees and their Trade Unions. TTP has 3 recognized trade unions. 1. Titanium Government Labour Union (TGLU) of (CITU) 2. Titanium Products Labour Union (TPLU) of INTUC) 3. Titanium Employee Co-ordination Council (TECC) of AITUCSTUUTUC etc. trade unions get reorganization on the basis of referendum. Workers Participation The further enhancement of industrial relation is done by encouraging workers and increasing worker‟s participation in management. For this purpose TTP has formed various committees like Works Committee Canteen Advisory Committee Departmental Promotion Committee Medical Committee Benevolent Fund Committee Safety Committee etc., in the works committee the members are selected representatives of workers and management. They met once in a month. Communication There is an effective communication present in TTP with the Employees and Management. There is upward and downward channel present. In TTP, suggestion boxes are present for

Page

20

the suggestions of employees to the management. It helps tier communication very easy.


Industrial Training Report: Travancore Titanium Products Canteen TTP directly running and industrial canteen to cater the needs of the employees at subsidized rates-functions under the control of personal department, works round the clock is headed by canteen Superintendent. A flat rate system has been introduces and deduction is made from salary/wages of the employees. It is the duty of the supervisor to check quality of foods. TTP purchase vegetable and other through purchase section form Government agencies on contract basis. 3.5

COMMERCIAL DEPARTMENT

In TTP, the Purchasing department, Sales and contract department are came under one department namely, Commercial Department. The job of this department is procurement of all materials and services and sales of finished goods resulting in fulfillment of production and sales objectives of the company. The common function of the commercial department is to make dealings with KSIPTC. Purchasing Section Purchasing is the most important function of materials management as the moment an order is placed for the purchase of materials, a substantial part of company‟s finance is committed which affects cash flow position of the company.

The main objective of purchasing

department is to see that the required quantities at the appropriate time and of reduced price. The purchasing department concerned with purchase of all spares and materials except raw materials for all department. The main Objectives of the department include 

That financial and legal interest of the organization related to purchase activities are safeguarded and that timely supply is guaranteed.



The quantity of materials purchased should be tested and certified by a competent officer from the department/stores.



To develop good suppler relationship which will ensure the best terms of supply of

To serve as an Information Centre on the materials knowledge relating to price, source of supply, mode of delivery etc.,


Page



21

materials.


To make continuous availability of materials so that there may be uninterrupted flow of materials for production.



To make purchase in reasonable quantities to keep investment in materials at minimum.

Activities and Procedure a.

User development gives the request to stores department and order Requisition is sent to purchase department.

b.

Vendors list is prepared and quotations are invited from seller.

c.

Processing of these quotations/tenders

d.

Purchase of pre-audit.

e.

Tabulation sheet, vendors list etc, is sent to user.

f.

Purchase post audit.

g.

Cancellation of purchase order.

h.

Settlement of suppliers bill.

Contract and Sales Section Contract department is mainly concerned with the disposal of scrap items. They are usually disposed off by giving contract to outside parties. TTP‟s scrap is mainly used for welding. These are produced by Steel Industries Ltd. Kerala (SILK). TTP‟s sale of their products usually through KSIPTC and therefore no Marketing section in TTP. There is no interaction between TTP and customer. Order are coming through KSIPTC. All the formalities of the sale are done through KSIPTC.

3.6 RESEARCH AND DEVELOPMENT DEPARTMENT Research is an ongoing process. For the development of any organization, research is a prime factor. So in any reputed organization, there is a special wing for research and development. TTP also has a well-equipped and efficient R & D Manager subordinated by 3 Managers concerned with Quality control and Pollution monitoring, Technical services, Research and

was able to find long-term solution to certain problems of process and quality. The R & D Manager was responsible for guiding, directing, initiating and executing all the jobs in the


Page

processes or techniques for the company. By the findings of these departments, the company

22

pilot plant respectively. The department was concerned with the research or study of new

Industrial Training Report: Travancore Titanium Products department. The ISI analysis of the products and raw materials also came under this department.

Research and Development activities are concerned with raw material

substitutions, usage norms, surface coating, development of titanium based products, pollution control, effluent control advice on stage wise inspection and follow-up of titanium dioxide production particularly Rutile grade. They have recently started the production of Rutile based titanium dioxide and the capacity of the plant is 15 tons/day. They are planning to import it to U.S.A. The credit of this achievement goes to R & D department. TTP gave prior importance to the quality of product. Their product was well known for its quality. TTP has a well-established Quality Policy is as follows. “To achieve customer satisfaction through conditions improvement of processes, production and human resource and by providing effective customer service.” The main Objectives of R & D department are: 

Render in process, stage wise testing and trouble-shooting service acting as a necessary adjunct to production.



Undertake development projects both for process and product improvement and diversification to help General Manager and advice management on new process, products and projects.



Identifying the changing needs of customers through regular interactions.



Maintaining quality at incoming in process and final product stages.



Implementing and maintaining a quality management system.

Taking samples at various stages starting from raw material till the end product.



Analysing the samples, finding the variance in production.



Studying the variance.



Finding the process parameters like electricity revelation per minute (rpm).



To improve the quality as well as quantity of products.



Monitoring the plant performance and pollution.



Maintaining quality at all stages of products.



Providing service to customers.


Page



23

The department has mainly some Functions which are.


Chief Commercial Manager

Commercial Manager

Deputy Commercial Manager

Assistant Commercial Manager

Section Officer Figure 3.3 Commercial Department: Line of Authority Research & Development Department Includes 5 Divisions Namely; 1. Research and Pilot Plant The pilot plant produces special grade of Titanium dioxide, sodium titanate and potassium titanate that are used in welding electrodes as flux. 2. Process Quality Control It is responsible for analysis of raw material, finished products and samples from different

Page

24

products process stages etc.


Industrial Training Report: Travancore Titanium Products 3. Technical Services It is responsible for providing service to customers. They analysis the final packed product for ISI grading and allow the same for the customers looking in for specific requirement and attends to customer‟s queries and complaints. 4. Pollution Monitoring It carries out the analysis of liquid effluent and also stacks emissions and reports the result to the State Pollution Control Board. The Research group is responsible for optimizing products quality and process specification, development of titanium based product on a bench scale and further on a pilot plant scale. 5. Library TTP has to Libraries, namely Technical Library and Titanium Recreation Club Library (TRC library), which comes under the R & D department. Technical Library has books of all subjects, which is under management control.

TRC library has daily newspapers and

magazines, which is under a committee Chairman is a Management nominee. There are 7 members in the committee.

RESEARCH & DEVE LOPMENT MANAGER

QUALITY CONTROL & TECHNICAL SERVICE MANAGER

Figure 3.4 Research and Development Department: Line of Authority


Page

JUNIOR CHEMIST

25

CHEMIST

Industrial Training Report: Travancore Titanium Products 3.7

MATERIALS DEPARTMENT

In TTP Ltd., even though the Materials section comes under the commercial department, it is functioning independently. In this company the investment in current assets constitutes a lion portion. Therefore a separate stores department is maintained. The location and layout of the department is carefully planned so that transportation charge can be minimized. The Materials section has many important functions. They are as follows: 1. In Ward Materials a. All the stores materials coming to the stores as per the different purchase orders made by the purchase section are received. b. The quantity and quality are checked and a receipt voucher is prepared. c. After the inspection of materials, quantify is recorded in the Bin Card and Kardex as per the location and code of each material. 2. Dispatch a. As per the delivery orders received from the commercial department, the customers of the various products sent their transporting vehicles through various transporters. b. The invoice declaration and gate pass is prepared. c. The materials produced daily is taken into stock and maintained in the register. 3. Inspection The receipt vouchers are checked for the item and the quantity and the concerned intend of the material is asked to inspect and certify. The inspector works in accordance to the concerned intends while receipt of goods. 4. Issues of materials The main function of this section is to issue the materials as per the issue voucher. This issue

Page

26

is also recorded in Bin Card and Computer.


Industrial Training Report: Travancore Titanium Products 5. Raw Materials The raw materials received from various sources i.e., departmental and contractor are recorded as per the weighbridge bills. 6. Inventory Control and Disposal The material section should also concern with the inventory control. They should inform to the concerned departments when the reorder level is reached. In TTP the store stock is managed by using “KARDEX” system. In this system every stock card has details regarding receipts issues and rejections and each card has a control code number of materials received and the receipt entry of which is made in Kardex card against respective code. Moreover each card mentions he entire specifications of the material. Above all there is an order for each card item. From the card itself we can get ordering quantity fixed on the basis of 5 yeas annual consumption. From the order card we can ascertain details of order requisition date and order quantity.

Chief Comm. Manager

Materials Manager

Dy.Manager (Material)

Asst. Manager


Page

Figure 3.5 Material Department: Line of Authority

27

Section offside

Industrial Training Report: Travancore Titanium Products 3.8

HUMAN

RESOURCE

DEVELOPMENT

AND

ADMINISTRATION

DEPARTMENT The department is headed by the Chief Manager (HRD and Administration). The department mainly concerns with the whole development of work force. For any organization, employees are the hidden assets. Without these employees no company can work effective. For the effective working, these employees and employers need development. This department is mainly concerned with the worker‟s training and executive development. Human resource is a complex one. So there is proper training for his working. This department of TTP functions in very efficient manner in this case. This department aims at increasing the attitude, skill and abilities of the workers to perform specific tasks. The training program provided at TTP started functioning from 1980s. Every training programme has a well-defined specific objective. The different Stages in Training as follows. 1. Induction Programme Induction programme is training with specific objectives. It aims at creating awareness to the new comers about the organization and its products, different sections, rules and regulations they have to follow etc. 2. Orientation This is the second stage in training programme. After induction programme is carried out, feedback is obtained after three months. This is orientation. This helps the trainers to learn new methods, skills and techniques. The training department of TTP mainly offers 4 main Training Programmes. They are, 1. Induction Programmes or Vestibule Training This programme is meant to induct the selected candidates into the work environment. This programme is designed to give them a general view of what the enterprises does, how it is

programme is 3-14 days.


Page

more elaborate in the case of supervisory and management employees. The duration of this

28

organized, what benefits it offers and what its general rules and regulations are. It can be

Industrial Training Report: Travancore Titanium Products 2. In-House Training Programme This programme is for improving behavior or the attitude of the employees. It is meant for all levels of employees and worked, aimed at creating an awareness of the knowledge of fundamentals. It is mainly for improving employee‟s attitude, motivation, co-ordination etc. under this programme and industrial tour was conducted which was for 8 days. The number of members for this four was 25 for visiting different types of industrial units and their activities. The duration of this programme is 5-6 days. 3. Outside-Training This programme is meant for particular category of employees or workers, conducted by the Training Department under the authority of specialized expert from outside agency. This is knowledge-based training. In this programme, an effort is made to expose participants to concepts, theories, basis principles, pure and applied knowledge in any subject area. The focus is essentially on transmission of knowledge. 4. Unit Level Class This programme is come under worker‟s education scheme. In this programme, education is given to the workers in order to create social awareness in tem. Education is given to workers in areas like their working environment, democracy etc. There is separate syllabus for this Scheme prepared by Govt. of India. The duration is three months. In addition to these main training programmes, the Training department of TTP also conducts programmes like. 3.9 ENGINEERING DEPARTMENT One of the major departments in TTP is the Engineering Department, which is headed by Chief Engineer. The Engineering Department is responsible for the installation of all factory structures, plants, equipment and their proper maintenance and upkeep as well as optimum production of titanium dioxide. The Department has four sections each headed by Deputy

Page

overall activities of all sections. TTP has a well efficient Engineering Department.

29

Chief Engineers under the authority of Chief Engineer. The Chief Engineer Co-ordinates the



Chief Manager HRD & Admn

Deputy Manager (SD)

Asst. Manager (T & PRO)

Training Officers

Asst.Manager (Admn)

Sectional Officer

Staff

Staff Figure 3.6 HRD and Administration Department: Line of Authority The Engineering department performs various functions very smoothly. It has co-ordination will other departments also. The Objectives of the Engineering Department includes. 

Planning, arranging and initiating preventive maintenance programmers and repair of equipments and installations in the factory including vehicles.



Ensuring proper upkeep maintenance and installation of estate.



To advice the Management to take decision on all Engineering matters.



To arrange planning of engineering equipments and stores materials required for the factory.



Preparation of technical specifications and assist the Commercial Department in technical scrutiny of offers and arranging purchase and stock of materials.



To keep liaison with Government Departments like KSEB, Electrical Inspectorate, Factories and Boilers Inspectorate etc. for ensuring maximum co-operation and

Preparation of plants.



Preserve the working life of plants.



To safeguard investments.


Page



30

assistance form these department for maintaining all engineering related activities.


Maintaining safety and efficient working condition.



To achieve minimum break downs.



Inspection of jobs at successive stages of production.



Ensure normal productivity.



Ensure availability of machine, building etc.

The Engineering Department in TTP has four major subdivisions namely Electrical, Mechanical, Instrumentation and Civil Sections. A brief description about each section is as follows. Electrical Section One of the major sections of the Engineering Department is Electrical Section-which is headed by Deputy Chief Engineer. This section under takes the activity of maintaining substations of 60/11 KV and 11/440KV power demand of the factory. The main function of this department is the electrical maintenance of plant and organization. The maintenance of different types of electrical equipments like switchgears, motor control center, power control center and different types of motors etc. The areas like white section and black section of plant, Generator substations and Sulphuric Acid Plant came under this section. Electrical Workshop The electrical section has well equipped workshop, which undertakes electrical works of the company. The major functions include. 

Maintenance work of electrical equipments



Inspection of electrical items.



Undertaking electricity related works.



Instrumentation work and telephone maintenance.

Mechanical Section Another section of Engineering Department is the Mechanical section, which is headed by

Technical Services, Titanium dioxide plant and Vehicles, SAP, Boiler & Utilities. Functions of mechanical section includes maintenance of equipments, machines etc. Plant Technical Service (PTS) carried out statutory work of company.


31

This section includes areas like Workshop and Plant

Page

three Deputy Chief Engineers.


Repair



Maintenance of Mechanical devices and equipments.



Maintenance of spare parts.



Installations and running of the related devices.

Instrumentation Section Instrumentation department enhances maintenance of instruments, modification of works etc. The areas like titanium dioxide plant, shift, acid plant, lab instruments, weigh bridge, Attendance Management System are also come under this section. The section enhances Titanium Plant service maintenance as well as that of acid plant. The function of this section includes process parameters are done by this section. Daily charts and monthly charges are present. This section conducts service contracts for checking weighing bridge. This section also deals with punching system repair. The TTP has electronic punching machines, which was filled by KELTORN. Attendance Management system is also another function of this section. Civil Section The civil section is one of the major sections of Engineering department. There are 16 labours present in the section, which includes officers. They mainly undertake Plant maintenance work. The section has co-ordination with stores and Commercial Department. The main activity of civil section is construction and extension of building and also the maintenance of carpentry works, plumbing works etc. There is a separate drawing branch for drawing the outline of new projects in Civil Section. 3.10 FINANCE DEPARTMENT Finance department is the lifeblood of the business. So in any organization the most important department is the Finance Department. Without this department no company can work smoothly. TTP also has an efficient department for Accounts and Finance headed by Finance Controller. Finance Department is concerned with planning and controlling of the



Preparation of corporate plans annual plans and budgets.


Page

The important objectives of the finance department include.

32

firm‟s financial resources.


Financial planning cost control and ensuring uniform and correct observance of financial disciplines of the company.



Monitoring the progress of budget achievements.



Providing accounting service to all levels ensuring updating of systems procedures for the same.



Advising management on funds utilization and its implementation.



Vetting of all investment proposals, certain of new assets, new posts etc. from the point of financial feasibility.



Evolve an audit manual.

The finance department performs various functions very effectively. The Main functions of this department include: 

To collect all sums due to the company in time as per sales, orders etc.



To make timely payments to creditors, suppliers, contractors, employees, Government statutory bodies, service provides etc.



Timely dispersant of salary/wages/perks to employees as per agreement, MOU etc.



To assist all types of audit work.



To prepare MIS as required by management.



To complete all Budget work.



To manage cash properly to maintain proper liquidity.



To assist all departments in providing financial administration of all transactions.



To make proper entries in boos of accounts and extract reports like Trial Balance, P & L A/c, Balance sheet on a time bound basis.

Significant Accounting Policies: Every organization has its own accounting policies.

TTP also has its own accounting

policies. The following by the company: 1. Fixed Assets

are consistently being recorded at historical costs to the company and therefore they are not adjusted to reflect the change in value in the purchasing power of money.


Page

relating to the acquisition and installation of fixed assets are capitalized. Assets and liability

33

Fixed assets are started at cost of acquisition or construction less deprecation. All costs

Industrial Training Report: Travancore Titanium Products 2. Investment All investment are valued at cost. 3. Inventories a. Raw materials, materials in process and stores and spares are valued at the cost on weighted average method. b. Finished goods – Titanium dioxide is valued at cost. c. Goods in transit are valued at cost. 4. Sales Sales are exclusive for excise duty and sales tax. 5. Depreciation Depreciation on fixed assets has been provided as per the rates prescribed in schedule XIV of the Company‟s Act of 1956. Under written down value method depreciation on additions and deletions of fixed assets is calculated on prorate basis. 6. Retirement Benefits Gratuity liability is provided based on the company rules prevailing from time to time. The gratuity fund created to the company has been approved by the income tax authorities. The net asset of enable the fund to fully discharge the company‟s obligation in respect of gratuity, payment to the employees etc. The liability to pay leave encashment accrues only when the employees can encash unveiled leave during their period of service till the employee exercise his rights. Hence it is not quantifiable and is accounted on cash basis. 7. Scraps Accounting of scrap is done at time of sale. In finance department, there are several sections such as salary/wages, provident fund, loans, over time work allowance darkness allowance

There are several sections in the department of finance. They are:


Page

Sections in Finance Department

34

etc. Each section is handled by one or two persons.

Industrial Training Report: Travancore Titanium Products 1. Bills Section 2. Loan Section 3. Stores Accounts Here proper maintenance of stores accounts and proper balancing and recording of each and every transaction is done. 4.

Salary and Wages section:

Timely payment of benefits including salary and wages to the employees is under the charge of this section. Finance Controller

Finance Manager

Asst.Manager Computer cell

Section Officer Computer Cell

Dy.Finance Manager (1)

Asst. Manager Stores Accounts

Asst. Manager (Bills)

Section Officer (Bills

Dy.Finance Manager (2)

Section Officer Stores

Section Officer Final Accounts

Asst. Manager time Office

Section Officer Tax/ Budget

Dy.Finance

Asst. Manager Salary/w ages

Section Officer time Officer

Section Officer Salary/ wages

Asst. Manager Cash

Section Officer Cash

Section Officer Loans

Figure 3.7 Finance Department: Line of Authority


Page

35

& PF

Industrial Training Report: Travancore Titanium Products 5. Cash Section Cash section is in charge of preparing cheques on receipt of vouchers, on receipt from bank and they maintain a petty cash book for entering expense including during business hour, which includes monthly salary and incentive payments and other payments. 6. Computer Cell The Computer cell in TTP started functioning since 1994 with assistance from ER & DC. Today almost all the departments of the company are computerized. Various sections of the company are connected to Local Area Network (LAN). 7. Time Office Time Office is for recording the attendance of the workers. This section is under the authority of Finance Controller. The manual card punching is facilities in time office. The electronic card punching system is on trial stage and facilities in office building entrance for employees. Simultaneously the attendance registers were kept in each department.

3.11 SAFETY DEPARTMENT Workers are the hidden assets of any organization. So TTP gives prior importance to the safety of its employees. The safety department is concerned with this function. Safety management is a statutory requirement in any organization and its objective is to ensure the safety in the factory premises. This department has an advisory function, which gives advice to different department such as Production Department, Engineering Department etc., and also to top management on various safety matters. They also give advice to workers handling hazardous equipment and chemicals. This department is mainly concerned with control of accidents and losses occurred within the company.

This department defects unsafe

conditions and actions and they report it to the top management.

To control accidents and losses.



To detect and prevent work related accidents.



To give instructions to work force about safe working methods & conditions.



Providing and maintaining safety equipments and guards.



To advice and assist the factory management for fulfillment of its statutory obligation.


Page



36

The main Objectives of the department include


Monitoring the potential health and safety problems and carrying safety inspections.



To carry out the company‟s safety policy smoothly.

The company‟s Safety Policy should also set out the health and safety rules covering. 

Safe working health.



Inspection of new equipments



Testing of equipments



Inspection of the working premises etc.

The various personal Protective Equipments that the company provided for the employees are. Table 3.1 Protective Equipments Helmet

For head

Goggles

For eyes

Mask

For face

Respiratory Apparatus

For Breathing

Gloves

For Hand

Apron

For Body

Safe Shoe

For Foot

Above all these, the safety department has peculiar functions of its own which makes it an important one. These Functions are the following. 

To direct unsafe conditions and actions in the working premises and report it to top mgmt.



To control the losses and accidents that occurred within the company.



Give medical and other type of assistance in accidents.



To provide preventive action, which include plant safety inspection, safety audit,

To create safety awareness among the employees.



To conduct investigation about the accidents that occurred.



To analysis the accidents occurred in an year and calculate the severity rate.

Page



37

periodic training programme for accident prevention etc.



Safety Manager

Asst. Safety Manager

Supervisor

Section Officer Figure 3.8 Safety Department: Line of Authority 3.12 MEDICAL DEPARTMENT In TTP Ltd, there is a Medical section. Even though it comes under the authority of Personal department, it is functioning independently for providing better service to the employees. The head of the section is a Medical Officer. Under him, there is one male nurse and four nursing assistants. The Medical Officer and male nurse were working a general shift. The employees working in areas hazardous to their health are subjected to annual biotexological examination at Occupation Health Service Centre, BHEL and Trichy, Periodical medical checkup for employees in Canteen, led burning, packing shed, acid plant and welding section are conducted. Ophthalmic checkup for the employees was organized in collaboration with ophthalmic outpatient unit of General Hospital, Thiruvananthapuram. Supplementary vitamin foods were being given to these employees. The medical allowance given to the employees is ¼ th of the amount of sum of basic pay and D.A, which is paid once in 3 months.

Doctor is recorded in it with the date of consultation and the book is kept with the section. The ambulance and driver is present for 24 hours service. One sick assistant is also present.


Page

also. Each employee has a medical record book with him. The treatment and findings of the

38

There are two sections- Ayurvedic and Allopathic and each section has one Medical Officer


Company Medical Officer

Male Nurse

Nursing Assistants Figure 3.9 Medical Department: Line of Authority 3.13

SECURITY VIGILANCE DEPARTMENT

The main objective of the Security and Vigilance Department is to ensure the smooth functioning of all activities within the organization. The movement within the company premises is controlled by this department including movement of men, material, vehicles etc. This department is responsible for the issue of Identity Card, In pass and Out pass. Only authorized people are entitled to enter into organization. This department is headed by a Security Superintendent and Vigilance Officer and he is directly answerable to the Managing Director. Duties and Responsibilities 

It is responsible for the Safety & Security of all property.



To safeguard the company‟s functions.



To assist the police department during disputes and emergency situations.



All the records, registers, file order etc. connected with the documentation work at the main gate shall be kept in order and maintained properly.

personnel, material and vehicle either attached to the company or connected with company‟s business or any other business.


Page

It is the duty of the Security guard at the main gate to monitor all the movements of

39

Duties at Main Gate

Industrial Training Report: Travancore Titanium Products Duties at Main Office The security guard posted at the Time Office regulates all the entry and exist of workers during the stipulated shift timing.

He should carry out cursory check on all outgoing

workman.

Managing Director

Security Superintend

Vigilance Officer Figure 3.10 Security Vigilance Department: Line of Authority

3.14 PROJECT DEPARTMENT The company takes projects on recently. So the importance of Project Department gains its importance recently. This is a new department specially created for carry out the project works successfully. Company identifies the scope of the project works recently. So it is essential to fix a special department for this. The project department in TTP, Which is headed by chief Project Manager, carry out the projects for the company. They also dealt with plant modification and expansion. Under the authority of Chief Project Manager, three wings are present civil, mechanical, and project wing. The project department undertakes the type of works like. Plant Modification and Expansion

with this duty.


Page

gives prime importance to the modification of the plant. Project department is concerned

40

Plant Modification and Expansion is very important concerned with the company. Company

Industrial Training Report: Travancore Titanium Products New Projects Company undertakes several new projects. Pollution is the main problem faced by the company. So company needs a project for pollution controlling. So this project department undertakes a new project for pollution controlling and other new projects. Steps in project implementation 1. Feasibility Report The project team in the unit will prepare the feasibility report, based on the existing as well as predicted demand, economic viability, technical feasibility and other aspects of the projects under evolution. 2. Submission and approval to Unit Head. 3. Design and details. 4. Procurement of equipments 5. Plant installation 6. Commissioning and trial running.

Chief Project Manager

Project Manager

Asst. Executive Engineer (Mech)

Executive Engineer Civil

Asst. Executive Engineer (Project)

Asst. Executive Engineer (Civil)

Page

Figure 3.11 Project Department: Line of Authority

41

Executive Engineer (Mech)



3.15

MARKETING DEPARTMENT

The Marketing Department of Titanium mainly concentrate on sales. Sales No direct sale of Titanium Dioxide us done. Orders are collected through Kerala State Industries Product Trading Corporation (KSIPTC). Since there is no separate marketing division in Travancore Titanium Products Ltd., the government appointed KSIPTC to sell their products on 1% commission basis. Different sales in TTP Ltd ISI grade Titanium Dioxide is mainly used in paint industries. General purpose Titanium Dioxide is used in leather industries. Special grade Titanium Dioxide is used for welding purposes. How to sale the product in Titanium? 

Domestic Sale



Stockiest

Mode of Sale 

Purchase Order o Scrutinizing purchase order o Quantity requirement o Quality requirement o Price



Intent Raising name of purchaser



Allocation of Material by R & D Department



Invoice



Dispatching Materials

Page

If these conditions are satisfied then only the marketing department will start to work.

42

o Mode of Transport


Industrial Training Report: Travancore Titanium Products Promotion Titanium will promote their product by four ways which are through 

Magazine and News papers



Exhibition



Television (Rarely)



Internet

Chief Manager

Deputy Manager

Assistant Manager

Section Officer

Section Officer

Staff

Page

43

Figure 3.12 Marketing Department: Line of Authority



CHAPTER 4 PLANTS AND PROCESSES Two main plants in Travancore Titanium Products are 1. Titanium Dioxide Plant 2. Sulphuric Acid Plant 4.1

TITANIUM DIOXIDE PLANT

Production of Titanium Dioxide Titanium Dioxide is mainly produced from the raw material illmenite, which is a complex compound of oxides of titanium and iron. Table 4.1 Composition of illmenite. Kollam Grade

MK Grade

Titanium Dioxide

59-60%

53-54%

Ferrous Oxide(FeO)

09-10%

25_26%

Ferric Oxide(Fe2O3)

24-25%

15-16%

Oxides of other elements

05-08%

04-07%

Process The two main processes for the separation TiO2 from Ilmenite are 1. Sulphate process 2. Chloride process TTP Ltd is using the sulphate process. Raw Materials The major raw materials used are 1. ilmenite 2. Sulphuric Acid 3. Scrap Iron

6. Pottasium Sulphate(K2SO4)


Page

5. Aluminium Dust

44

4. Glyceryl Mono Stearate

Industrial Training Report: Travancore Titanium Products 7. Mono Ammonium Phosphate Process Description The production of TiO2 from ilmenite requires a number of operations and some unit processes. The various sections in the route for its production are 1. Grinding 2. Digestion 3. Clarification 4. Concentration 5. Precipitation 6. Post precipitation filtration 7. Pre precipitation filtration 8. Leaching 9. Post Leaching filtration 10. Treatment 11. De watering filtration 12. Calcination 13. Pulverization 14. Packing Here TiO2 (Anatase) is the main product. 1. Grinding Ilmelite is brought to this section from godown using the belt conveyor. The purpose of grinding is to reduce the size and hence to increase the surface area of the ore to achieve maximum reaction efficiency. Here the equipment used for grinding is a ball mill.

Ball mill

2.

Rotary classifier

3.

Mill fan

4.

Double cone classifier

5.

Cyclone separator

6.

Viscobeth


Page

1.

45

The main sections of a milling are

Industrial Training Report: Travancore Titanium Products 7.

Ductings

8.

Dampers

9.

Vent Pipe

Working The material is fed into the ball mill from silo using constant weight feeder. By the action of the fan the ground product along with the air is sucked into rotary classifier, where the coarser particles are sent back to the mill for regrinding. Then the air product mixture is sucked into the double cone classifier, where the oversize is separated and sent back to the mill. The air leaving the double cone classifier with the required size particles reaches the cyclone separator where a whirling action prevails. The product is separated and sent into a bunker through an air locked rotary valve connected at the bottom of the cyclone separator By the action of the mill fan, air is discharged into the ball mill, at the same time air leaving the cyclone separator is sucked by the fan. Air from atmosphere enters at certain regions of the ductings, so suction increases over discharge which may imbalance the whole system. In order to prevent this condition, extra air is removed through a vent pipe to the atmosphere. ILMENITE

CLEANING

FILTRATION

PRE LEACHING FILTRATION

PACKING

MILLING

GRINDING

PRECIPTATION

LEACHING

COOLING

DIGESTION

CONCENTRATION

POST LEACHING FILTRATION

CALCINATION

REDUCTION

SETTLING

TREATMENT

DEWATERING FILTRATION

Page

46

Figure 4.1 PRODUCTION PROCESS (Diagrammatic Presentation)


Industrial Training Report: Travancore Titanium Products 2. Digestion Digestion is the second section in the manufacture of TiO2 pigment. It consists of five stages. 1. Reaction 2. Baking 3. Dissolution 4. Reduction 5. Final Adjustment Digestion is a Reinforced Cement Concrete (RCC) cylindrical vessel conical at the bottom. It is first lined with lead and then a double layer of acid resisting bricks. The necessity of having a RCC vessel is to withstand the pressure and vibrations that develop during the reaction. The consistent unit to the digester are trident and service line, sturm box with the strainer bottom „T‟, service „T‟, stand pipe and fume cupboard with exist stack. The three arms of the trident are connected with compressor airline, water line and stream line, and the common service line from the trident enters at the bottom of the digester through the service „T‟, and bottom „T‟. The other lines entering through the top digester cover are the ground ilmenite, weak liquor and cutting water inlet lines. FeO+H2SO4

FeSO4+H2O

Fe2O+3H2SO4

Fe2S(O4)3+3H2O

TiO2+3H2SO4

TiSO4+H2O

FeOFe2O3. TiO2+5H2SO4 + Fe2 (SO4) + Fe2(SO4)3 + TiOSO4 + 5H2O 3. Clarification The crude liquor is sent to a settler which is the equipment used for settling operation. Reduced liquor contains unreacted ilmenite, residue due to scrap iron and finely divided

Page

47

colloidal particles which are to be removed.


Industrial Training Report: Travancore Titanium Products Settling Operation The settler is actually a thickener. This is as large fairly shallow tank with slow moving radial rakes driven from a central shaft. Its bottom is conical. Dilute feed slurry flows from an inclined trough or launder into the centre of the thickener. The feed flurry being more denser than water tends to flow downward until it reaches a zone of equal density. Then it moves radially outward at a constantly decreasing velocity and the flow gradually divides between the downward moving suspension and the upward moving flow that is nearly free of solids. Liquor moves radially at a constantly decreasing velocity allowing the solids to settle at the bottom of the tank. Clear liquor is obtained as the overflow. The rake arms gently agitate the sludge and move it to the centre of the tank, where it flows through a large opening to the inlet of a sludge pump. Here the feed is fed into the settler through a feed well, so that it will not spread at the top but reaches the centre. The temperature inside the settler is minimum 600C. An organic flocculent is used which causes agglomeration and hence faster settling of particles. Clear overflow is obtained from the top through pipes connected around the settler. The rakes rotating at a speed of 1/13 rpm gently agitate the sludge and move it to the centre of the tank. The overflow from the settler contains TiOSO4 andFeSO4 in acid medium which is collected into the SLS tanks from where it is pumped to the concentration feed tanks. Weak Liquor Preparation The sludge from the settler is withdrawn through the bottom valve and sent to the sludge dilution tanks. After specified quantity is withdrawn it is diluted to the required specific gravity and pumped to sludge settlers. Weak liquor overflow from the sludge settlers is collected in weal liquor storage tanks. 4. Concentration The overflow from the settler has a concentration of 140gpl. The purpose of the concentration is to increase the concentration of the liquor by evaporating the water content and hence to

1. Concentration feed tank


Page

There are 3 concentration units. The main parts of concentration unit are

48

increase the content of solids in the liquor per litre.

Industrial Training Report: Travancore Titanium Products 2. Overhead tank 3. Preheater 4. Concentrator 5. Vapour separator 6. Discharge lute Working The liquor from the concentration feed tank is fed to the overhead tank from where it is fed to the preheater. Preheater is a shell and tube type Heat Exchanger. There are 22 tubes inside the preheater. The tubes and shell are made of electrolytic copper. The liquor from the preheater is fed to the bottom of the bottom of the concentrator. The concentrator has 32 tubes inside it which works independently. The tube side is made of electrolytic copper and the shell side is made of mild steel which has insulations to prevent heat loss. The shell side is fed with fed with steam. The liquor when passes through the tube side gets the water content reduced by evaporation. The concentrated liquor and vapour are sent to the vapour separator. The liquor at the bottom of the vapour separator is collected into the discharge lute. The vapour is sent to the preheater. Since the preheater is used, the amount of steam that is to be used in the concentrator is reduced and concentration is carried in less time with less expense and the once used steam can be recycled. 5. Precipitation Titanium Dioxide is separated from the concentrated liquor by precipitation. Precipitation is effected through thermal hydrolysis. Maximum precipitation takes place at a temperature of 1100C. The tank is made up of mild steel which has a brick lining inside made up of acid and heat resistant bricks which prevents heat loss and also protects mild steel. There is a rubber lining outside. The concentrated liquor at a temperature of 900C is fed into the tank. Nuclei is charged and kept for three hours. Steam is injected and cutting water is added. This brings

cooling.


Page

sealed with steam and is maintained for 3 hours. Then it is left there for about 21/2 hours of

49

about precipitation by thermal hydrolysis. Temperature rises to about 1100C and the tank is

Industrial Training Report: Travancore Titanium Products TiOSO4 + 2H2O -- TiO(OH)2 + H2SO4 Hydrated titanium dioxide is precipitated. Ferrous sulphate remains as such. It will not precipitate. It is during the precipitation stage that the black liquor is changed to white one. Filtration Here rotary drum filter is used. It is a continuous vacuum filter. Here is liquor is sucked through a moving septum to deposit a cake of solids. The cake is moved of the filtering zone washed, sucked dry and dislodged from the septum, which then reenters the slurry to pickup another load of solids. Some part of the septum is in the filtering zone always, part is in the washing zone and part is being relieved of solids, so that the discharge of both solids and liquids from the filter is uninterrupted. Working of Rotary Drum Filter A horizontal drum with a slotted face turns at 1/3 rpm in an agitated slurry trough. A filter medium such as canvas covers face of the drum which is partly submerged in liquid. Under the slotted cylindrical face of the drum which is a second smaller drum with a solid surface. Between the two drums are radial partitions dividing the annular space into separate compartments each connected by an internal pipe to one hole in the rotating plate of the rotary valve. Vacuum and air are already applied to each compartment as the drum rotates. A strip of filter cloth covers the exposed face of each compartment to form a succession of panels.

There are three zones for a rotary drum filter 1. Catch up zone 2. Wash up zone 3. Drying and releasing zone The drum is kept in such a way that 1/3rd of the drum is immersed in the slurry trough. The slurry is sucked up by the catch up zone. A vacuum is used to create the suction. Solids remain on the surface of the filter cloth, and the liquid along with the dissolved impurities is

Page

50

sucked into the tubes.


Page

51



Industrial Training Report: Travancore Titanium Products At the top of the drum water is constantly sprayed which washes the pulp when it comes in the washing zone. The water and the dissolved ferrous sulphate are sucked into the tubes. As the drum rotates, when it comes down vacuum is released at some region and so slurry is released. There are 16 tubes inside which are connected to a single tube lead which leads to a catch pot. The fumes from the catch pot are sent to a water scrubber. The cleaned gas is sent to a common line, which is connected to a vacuum pump. The catch pot and the scrubber are water sealed. For maximum removal of ferrous sulphate and other impurities the filtration is carried in four stages. 1. Post Precipitation Filtration 2. Pre Leaching Filtration 3. Post Leaching Filtration 4. Dewatering Filtration 6. Post Precipitation Filtration The precipitated liquor from the batch storage is sent to the filtration unit. There are four numbers of post precipitation filters. Size Length

- 16 inch

Diameter – 08 inch

The pulp is diluted and is sent to the repulping tank. The repulped mass is sent to the preleaching filters. 7. Pre Leaching Filtration Four numbers of filters are available. The feed is from post precipitation filters and dorr tanks. The purpose of filtration is to wash off ferrous sulphate and increase the TiO2 content

Page

Specification: Specific Gravity- 1.231.25

52

in pulp. The filtrate goes to the dorr tank.


Industrial Training Report: Travancore Titanium Products 8. Leaching The purpose of leaching is to reduce the non-washable ferric sulphate to washable ferrous sulphate. As the pulp passes through different filtration operations, some ferrous sulphate may get converted to ferric sulphate due to aerial oxidation. Here Al dust is added along with particular amount of sulphuric acid. This produces nascent hydrogen which is a good reducing agent. 9. Post Leaching Filtration The leached pulp is washed and filtered for the specific gravity 1.291.30 and an iron content of 0.001gpl. Four numbers are available. 10. Treatment In treatment section specific amount of potassium sulphate solution and mono ammonium phosphate are added and K2SO4 is also added to improve the tone, texture, PH and quality. Mono Ammonium Phosphate is added to impart antirutile properties. No. of treatment tank in one stream is two. 11. Dewatering Filter The pulp is again filtered to remove the water present. In the dewatering filter the vacuum is adjusted in such a way that to get a solid of 37% in the pulp 12. Calcination It is the process of slow heating of the pulp, which takes hours, to reach the other end of the calciner. Calciner is a long inclined rotary kiln, cylindrical rotating at a speed of 1/17 rpm. Its inclination is towards the furnace end. Two numbers of calciners are available here. They have a capacity of 30 tons per day. The purpose of calciners is 1. To decompose hydrated titanium into TiO2 2. To remove residual acid.

fuel. Kerosene is sprayed into the combustion chamber using a blower. There are two


Page

The cake is dried in a calciner by burning it in the combustion chamber with kerosene as a

53

3. To develop crystal unit.

Industrial Training Report: Travancore Titanium Products calciners used. The dried up TiO2 is blown off into the combustion chamber in the form of crystals by the aid of induced draught fans and thus providing draught in the chamber. The TiO2 crystals is then passed through a cooler and passed onto the milling section. The temperature at the firing end 1200oC, is measured by R-type thermocouple. The temperature at the feed end 450oC is measured by S-type thermocouple. The temperature at the firing end is controlled at 1200oC by manually controlling the flow of kerosene to the blower. The gas produced is evacuated through the main dust which further splits into two with an ID fab provided in each of the two sub dusts. These gases are taken through a cooling tower and an electrostatic precipitator. 13. Pulverization TiO2 obtained after cooling is in the form of granules. This is transferred using belt conveyors to bucket elevator which in turn lifts the product and dumps into a silo having a capacity of 40 tons. The particle size is reduced in a Bradely Pulverizer Mill. Bradely Pulverizer is a pendulum type mill which powders TiO2 to a very fine size of about 625 mesh. The pendulum rotates vertically with close tolerances to the casing of the mill. To send the feed in required quantity and to prevent overloading and to increase milling efficiency an auto feeder is provided. The main accessories of milling are 1. Fan 2. Cyclone Separator 3. Viscobeth The product coming out of the cyclone separator is sent into the packing bumker. 14. Packing A weighing machine is kept below the bunker. TiO2 is filled into plastic sacks kept over the weighing machine. 25 Kg is fed in each sack and sacks are tied. This is then sent into the market. 4.2

SULPHURIC ACID PLANT

with 50 tons per day capacity was also started. In 1996 a new sulphric acid plant was


Page

Titanium Travancore Products Limited. During the expansion in 1965 a sulphuric acid plant

54

Sulphuric Acid is a main raw material for the production of Titanium Dioxide pigment in

Industrial Training Report: Travancore Titanium Products commissioned with Double contact double Absorption process with a capacity of 350 tons per day. 1.

Water Treatment Plant

Water treatment plant is a division of the sulphuric acid plant where the water(steam) necessary for the production of the acid is generated. For steam production PHD water is used. Equipments The main equipments used are 1. M.G. Filter (multi grade filter) 2. SAC unit (Strong Acid Cation unit ) 3. DE gas sump 4. SBA unit 5. Mixed bed 6. D.M. Storage Tank Multi Grade filter This is used to remove clay or wood. It has sand or gravel unit on the top and mesh arrangement on the bottom. The water at 2.5Kg/cm2 is given to the top of the filter. As it passes through large layers of the filter the large impurities are removed and rate of flow is 15m3/hr. SAC unit This contains a Zeocarbon resin which produces hydrogen. Chlorides of Magnesium, calcium etc. is removed in this unit. Oxides of carbon and sulphur is converted to carbonic acid and sulphuric acid etc. water leaving from this section has a ph. of 2.5-4 and regeneration resins is done using sulphuric acid. De-Gaser sump Water from SAC unit is sent here to remove the carbonic acid. Water is sprayed to sump from

Page

atmosphere.

55

top and air is supplied using a fan. The acid is converted to co2 and h2o and co2 is sent to


Page

56



Industrial Training Report: Travancore Titanium Products SBA unit (Strong Base Anion Unit) Water from the De-Gaser is sent here. In this section the acidity of water is removed. For that resins having OH ions are used. Conductivity is 6.8-7.5. Regeneration of resins is done by NaOH. Mixed Bed Water from the SBA unit has low acidity and high alkalinity is not best for steam production and so the water is demineralized using a mixed bed. It has two resins with the same principle of SBA and SAC units. Demineralized Water Storage Tank Water is demineralized and stored in a storage tank. The water for steam production is obtained by using water treatment plant at a temperature of 33-350c. The water is given to a boiler but the temperature has to be increased and so using a desecrator the temperature of water is increased to 90-1000c. 2.

Procedure for the Production of Sulphuric Acid

Sulphuric acid is produced by double contact absorption process. Sulphur is the main raw material. Sulphur is melted, filtered and then oxidized to SO2. SO2 is further oxidized to so3 by passing through a catalytic convertor having vanadium pentoxide v2o3 as catalyst. The converted so3 is absorbed in concentrated sulphuric acid. Then the absorbed sulphuric acid is converted to sulphuric acid. Description of the main steps The flow diagram of the DCDA process contains the following equipments 1. Melting pit 2. Burner 3. Convertor 4. Absorber 5. Scrubber

Page

a by-product of petroleum industry.

57

The raw material used for the large scale manufacture of sulphuric acid is sulphur. Sulphur is


Industrial Training Report: Travancore Titanium Products 1. Melting Pit The sulphur obtained may contain impurities like Selenium, Tellurium, ash, mud etc. so sulphur is to be purified to about100%. The purification is done by melting. When sulphur is melted the impurities present in it remain in the molten sulphur itself. Sulphur has a melting point of 1300c. Sulphur is stored in a sulphur go down. With the help of an electrically operated crane it is transferred to a silo. Ratted quantity is fed to the melting pit by using a belt conveyor. For melting the sulphur steam coils are used. The high pressure steam melts the sulphur at a temperature of 140-1500c and 6.27kg/cm2. The velocity of the molten sulphur is maintained ina specified value so that the easy flow of sulphur is achieved. The specific gravity Of molten sulphur is 1.8. The impurities in the sulphuric acid raises the temperature of sulphur from 130-1500c. In order to neutralize the acid impurities, which are produced by the contact of molten sulphur with atmospheric oxygen, sulphurous acid, hydrated lime is added at the rate of 250gm/tons of sulphuric acid produced. The undissolved impurities are separated by settling in the melting pit itself. The overflow from the melting pit is collected in a dirty pit. From the dirty pit sulphur is pumped to leaf filter . The leaf filter is in horizontal inclined position. The filterate from the leaf filter are collected in a clean pit. The temperature of molten sulphur is maintained at a value of 1300c and at a pressure of 2.5kg/cm2. If the temperature is below 1300c the pumping of molten sulphur becomes difficult and above that temperature causes firing of molten sulphur.

2. Burner The molten sulphur reacted with compressed air gives sulphur di oxide gas. A furnace is used for burning molten sulphur and compressed air. The furnace is a horizontal, cylindrical vessel with two sulphur guns. The length of the furnace is 7m and diameter is 4m. The furnace is made up of carbon steel, acid proof bricks and fire resistant bricks.

furnace using burners. Dry air from air drying tower is introduced into the furnace. The


Page

Molten Sulphur is pumped from a storage tank through heated lines and sprayed in to the

58

S+O2->SO2

Industrial Training Report: Travancore Titanium Products temperature of furnace is kept at about 950-10200c, otherwise leakage of sulphur takes place. The conversion is exactly 10.5% by mole SO2 Waste Heat Boiler-1 Before the gases are fed to the first stage of the converter, they are adjusted to the minimum temperature at which catalyst rapidly increases the speed of reaction, usually 425 to 4400c. For that purpose a waste heat boiler has shell side and tube side. SO2 gas at a temperature of 10000c is passed through the tube side and water is passed through shell side. Thus by the principle of heat transfer the temperature of SO2 gas is reduced to about 4350c and water gets converted to steam. But there is a chance for reduction the temperature below this value. So the outlet of the waste heat boiler is given to a mixing chamber where mixing of SO2 from boiler and furnace takes place. As a result the temperature of SO2 can be kept at 4350c. 3. Convertor The chemical conversion of sulphur dioxide to sulphur trioxide is designed to maximize the conversion by taking into consideration that 1. Equilibrium is an inverse function of temperature and a direct function of the oxygen to the sulphur dioxide ratio 2. Rate of reaction is a direct function of temperature. 3. Gas composition and amount of catalyst affect the rate of conversion and the kinetics of the reaction. 4. Removal of sulphur dioxide formed allows more sulphur dioxide to be converted. The commercialization of these basic conditions makes possible high overall conversion by using a multipass convertor. A four pass convertor is used for conversion in the sulphuric acid plant. It has 4 beds of ring and start type materials coated with vanadium pentoxide catalyst for better conversion. The conversion takes place in two stages.

Sulphur dioxide gas from the mixing chambers is given to the 1st layer of the 4 pass

59

convertor. The conversion reaction is 2SO2+O2->2SO3. This reaction is highly exothermic.

Page

Stage-1


Industrial Training Report: Travancore Titanium Products Thus the temperature increases to 6000c. If this conversion stream is directly given to the 2nd layer of the convertor then the catalytic bed may be spoiled. In order to avoid that condition the outlet from the first layer is given to a super heater. Super Heater The gaseous stream from the first stage of the convertor is given to the tube side of the superheater and stream is passed through the shell side. Then the temperature is reduced to 425oC. The outlet of the superheater is given to the second bed of the convertor where 28% of conversion of SO2 to SO3 takes place. The conversion raises the temperature of gas to 520oC. For cooling this gas before it is given to the third layer a hot heat exchanger is used. Hot Heat Exchanger The outlet from the 2nd layer of the catalytic convertor is given to the tube side of the hot heat exchanger. Hot gas is passed through the shell side. Thus the temperature of SO3 gas reduces to 430oC. The gas stream from the hot heat exchanger is given to the third layer of the convertor. In the third layer 6% conversion of SO2 to SO3 takes place and the temperature rises to 450oC. This completes the first stage of conversion of SO2 to SO3. For absorption of converted SO3 its temperature should be reduced. Thus a heat exchanger and an economizer are used. Cold Heat Exchanger The outlet from the third layer of the catalytic convertor is given to the tube side of the cold heat exchanger and cold gas is passed through the shell side. Then the temperature of the SO 3 gas decreases to 330oC from 450oC. Economiser-1 For the further reduction of the temperature to 1800C an economizer is used. In the economizer gas is flowing through the tube side and water is flowing through the shell side. Thus the temperature is reduced to 180oC. 4. a. Inter-pass absorption tower

the IPAT and gas is given through bottom. The temp of IPAT is 700c.


Page

in shape and the gas is absorbed in 98.5% sulphuric acid. The acid is sprayed from the top of

60

The SO3 gas from economizer-1 is absorbed in an interpass absorption tower. It is cylindrical

Industrial Training Report: Travancore Titanium Products In order to reduce the temperature of sulphuric acid before it is sprayed to IPAT and FAT a plate cooler is used. Water is passed through the plates and acid is passed in between the plates. Thus the transfer of heat takes place and as a result of this temperature of acid is reduced and water become steam. Stage-2 The unabsorbed SO3 gas from the interpass absorption tower is given to the 4th bed of the catalytic convertor which is at a temperature of 4300c and 5.75% conversion of SO2 to SO3 takes place in the second stage and temperature is increased due to exothermic reaction.

Economiser-2 It is similar to that of economizer-1 and having so3 gas in the tube side and water in the shell side. Reduction of temperature takes place and the outlet from economizer-2 has a temp of 1800c. The outlet gas is absorbed in final absorption tower.

4. b. Final absorption tower Second stage absorption of so3 gas is done in the final absorption tower. It is similar to IPAT sulphuric acid at 98.5% concentration and reduced temperature is sprayed from the top of the FAT and so3 gas from the economizer-2 is given to the bottom of FAT absorption of so3 results. The outlet of both the IPAT and FAT has the formula H2S2O7 (oleum) SO3+H2SO4->H2S2O7 The oleum is collected in acid pumping tank. Acid pumping tank The acid pumping tank having capacity of 150m3 and it is cylindrical in shape. In order to maintain the concentration at 98.5% dilution water is constantly given to the acid pumping tank.

a byproduct of acid collecting tank steam byproduct of acid plant.


Page

pumping tank becomes greater than 150m3 it is transferred to the acid collecting tank steam is

61

There are six acid collecting tanks in acid plant. When the volume of sulpuric acid in the acid

Industrial Training Report: Travancore Titanium Products Air circuit Air for sulphur burner is supplied by electric blower is used. During the starting of the acid plant and power failure condition electric blower is used. All the other time, steam turbine blower is used. Air from the athmosphere is sucked through a filter for removing dust and compressed by turbine driven air blower and it is given to air drying tower to remove entire atmospheric oxygen. During is done with the help of sulphuric acid. The dry air given to the burner for burning of molten sulphur. 5. Pollution Control (Scrubber Unit) Gases from the final absorption tower contains SO2. SO3 atmospheric pollutant. Gasses from the final absorption tower are taken to a packed scrubber. During normal operation the gasses passes through dry scrubber. During start up or disturbed conditions caustic solution from the solution tank is fed to the foot of the scrubber by gravity. SO2 from the gases is absorbed in the circulating stream of caustic solution. Scrubbed gases are vented to atmosphere through a 26 meter tall chimney. The specified limit is 300ppm SO2, 100mg/Nm3 of SO3, as prescribed by the pollution control standards. Pre-commissioning of Plant Before the plant is made ready for commissioning, it is necessary that individual sections of the plant are checked and necessary test carried out on the equipment to ensure their smooth functioning during commissioning and normal running of the plant. Preheating The main step in pre-commissioning activities for first start is drying of bricks in sulphur furnace, startup furnace and convertor. Drying of brickwork shall be carried out by wood firing is sulphur furnace startup furnace and convertor. Sulphur Circuit

2. Fill sulphur melter with sulphur through the belt conveyor. Once substantial amount of sulphur is added to melter, start steam in melter coils and check for proper


Page

any dirt and scale etc.

62

1. For first startup clean all sulphur pits. Flush all the steam coils by steam to remove

Industrial Training Report: Travancore Titanium Products operation of traps. Allow the sulphur to melt and gradually go on adding solid sulphur till level of liquid sulphur is above the agitator level. 3. Now start the sulphur agitator, check the amperage of agitator motor, also check for any vibration on sound and start feeding sulphur gradually and continuously at maximum possible rate without any lump formation in sulphur pool. 4. Add lime accordingly to neutralize acidity. After sometime sulphur will overflow to dirty sulphur pit. 5. At this time start steam flow through coils in dirty sulphur pit. When liquid sulphur level comes to agitator level and check for smooth operation. 6. Open steam in dirty sulphur jacketed pipe and heat the same. Once sufficient amount of liquid sulphur is filled in dirty pit, start sulphur pump to recirculate sulphur. Once smoother operation of dirty sulphur pump is established transfer the sulphur to precoat pit and fill the same. 7. Add filter aid and start the agitator in precoat pit. Now system is ready for precoat operation of sulphur filter. Start steam in all jacketed pipes and in jackets of sulphur filter. 8. For filling the sulphur filter, first start steam in jacket and ensure that all are well heated. Ensure that lid flanges are tightened properly. Open the vent/overflow valve and start precoat sulphur oump. Keep sulphur valve position in suitable open/close position. Once sulphur starts overflowing close vent valve and allow the sulphur to recirculate in precoat pit. 9. Once the precoat cycle is over filter cycle can be started. Adjust the valves so that low from duty sulphur pump goes to filter and then to clean sulphur. If found in limits continue the filtration cycle. In case of ash being excessively check for possibility of improper precoat or damaged filter leaves. 10. Once the filtration cycle is over as indicated by reduced sulphur flow in filter outlet, prepare to open and clean the sulphur filter. 11. Keep clean sulphur tank sufficiently full well before scheduled date of sulphur firing. Take a trial of clean sulphur pump and circulate sulphur in all relevant pipelines. Normal Operation

improper precoat or damage to the screen. Take the corrective action accordingly.


Page

1. Check the ash content in sulphur once in a shift. Higher ash content may be due to

63

Sulphur Section

Industrial Training Report: Travancore Titanium Products 2. Choking of filter as indicated by reducing in sulphur flow indicates filtration cycle. At such time arrange for cleaning sulphur filter. 3. Analysis ash content and acidity of dirty sulohur feed to filter. This will ensure corrosion free operation and help in anticipating filtration cycle. 4. Incase filter aid contains chlorides wash the same thoroughly before feeding to filler to avoid corrosion Gas circuit 1. Analyse SO2 at convertor inlet regularly. Plant is designed to operate at 10.5% SO2 convertor inlet. 2. Convertor 2nd bed inlet temperature can be controlled by operation of super heater bypass valves. 3. Inlet temperature of 3rd pass is controlled by hot heat exchanged tube side bypass valve. Acid Circuit 1. Amperage of circulation pump should be noted regularly. 2. Acid samples should be analysed once a day check operation of analyser. 3. Level indicator readings should be checked frequently by manuel level measurement. 4. Observe flow of acid in tower distributor once a day through sight glasses. Boiler circuit 1. Check boiler feed water sample and boiler blow down sample once a day. Any abnormality observed it should be corrected immediately in water treatment, chemical closing or blow down frequency. 2. Ensure that steam flow is deaerator is maintained and BFW is at a temperature of 1001050c. 3. Safety valves should be checked regularly to ensure safety of high pressure equipment. 4. Level gauges should be drained and checked once a shift. 5. In no case boiler water level should be allowed to go below normal level 6. While operating boiler feed water pump, corresponding recirculation line valve

Page

64

should be kept open.


Industrial Training Report: Travancore Titanium Products General Guidelines for Good Operation 1. Always have a spare sulphur gun for service 2. When plant is shutdown, leave steam flowing through the sulphur burner jacket. This will serve as a coolant to protect the gun from the radiant heat until the furnace refractory has cooled. 3. Repair any shell or duct leaks at the earliest opportunity and repair all insulation. 4. Avoid use if cold feed water to an operating boiler except in an emergency. 5. Never allow the boiler exit gas temperature to drop below 2750c. 6. Although convertor-operating conditions will vary with time and service, never allow the catalyst temperature to exceed 6200c. 7. Elevate catalyst temperature slightly before a hot shutdown to facilitate startup. 8. Frequently check all thermocouples especially convertor thermo couples against a standard. 9. Never attempt to operate plant without acid circulation on all three towers. If a pump fails and cannot be restarted immediately shut the plant down. 10. Keep the spare acid pump in excellent condition and ready for quick start. 11. Verify the reading of conductivity meters once a day. 12. Try to keep acid plant circulating pumps running all the time, whether the plant is operating or not, if it is necessary to stop circulation for maintenance reasons, check the distribution section and clean if needed. 13. Establish and rigorously follow a procedure for collecting and recording data on plant operations. These would include temperature and pressure profiles of systems. Shutdowns In any shutdown, the first thing to turn off is the sulphur feed. For hot shutdowns, the blower should be turned off immediately after the sulphur is turned off. For shutdowns, those are expected to last more than 5-10 min; the acid cooling water should be turned off. Do not stop the circulation of acid over the towers unless it is necessary to do so. When possible increase catalyst temperature a few degrees before shutdown. These will simplify the subsequent start

Page

65

up. Make sure that dilution water is cut off.



Table 4.2 Temperature and conversions in each stage of the 4-pass convertor Location

Temperature °C

Gas entering 1st pass

430

Gas leaving 1st pass

600

Rise in temperature

170

Gas entering 2nd pass

430

Gas leaving 2nd pass

520

Rise in temperature

90

28%

Gas entering 3rd pass

430

6%

Gas leaving 3rd pass

450

Rise in temperature

20

Gas entering 4th pass

430

Gas leaving 4th pass

445

Rise in temperature

15

TOTAL

Equivalent conversion

60%

5.75% 99.75%

Shutting Down for a Prolonged Period Before shutting down for a prolonged period allow the strength of the process acid run up to 0.1-0.2% above normal operating strength. This will serve as a buffer against the small decreases in strength normally observed during a prolonged shutdown. Then stop dilution water. Turnoff the sulphur feed, and reduces the dry airflow to about 50% of design. Cool all catalyst leads with air to about 500c at a rate not greater in the boiler approaches atmospheric

Page

vacuum inside boiler. If the boiler is to be entered during shutdown, cool raw water may be

66

temperature, the vent valve on the steam drum must be opened to prevent formation of


Industrial Training Report: Travancore Titanium Products used as feed water after all steam generation has stopped, and the circulation. A boiler should

Page

67

not be drained until it is cooled throughout.



CHAPTER 5 CONCLUSION The Travancore Titanium Products Ltd is a well reputed, profit making Indian Company with an annual turnover of about 80 crores. The company is a boon to India, as its main product, Titanium dioxide forms an essential ingredient of almost all items used in our day-to-day life. T.T.P Ltd has monopoly over its products, TiO2. The major asset of this company is skilled staff. Moreover the efficient management of the resources have helped them to overcome the slump in the sales over the last few years. Through this In-Plant training it was able to fulfill the objective of our study. Detailed study on the processes was made possible by giving emphasis on the practical side of the theory. All together it was a good experience to see the company and various processes carried out in

Page

68

the plants and the various functions of the company.



REFERENCES [1]. www.wikipedia.org [2]. www.scribd.com [3]. www.google.com [4]. www.travancoretitanium.com [5]. www.indiamart.com

Page

69

[6]. www.bombayharbor.com


Travancore Titanium Products Industrial Training report

Recommend Documents